DODGE TOWN AND COUNTRY 2004 Service Manual

ASSEMBLY - ICU
(1) Install the CAB (Fig. 24) on the HCU.
(2) Install the 4 bolts mounting the CAB (Fig. 23)
to the HCU. Tighten the CAB mounting bolts to a
torque of 2 N´m (17 in. lbs.).
(3) Plug the pump/motor wiring harness into the
CAB.
(4) Install the ICU in the vehicle and bleed the
base and ABS hydraulic systems. (Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL/ICU (INTE-
GRATED CONTROL UNIT) - INSTALLATION)
INSTALLATION
INSTALLATION - LHD
(1) Place the ICU in its bracket below the master
cylinder. Start the upper mounting bolt to hold it in
place.
(2) Inside the vehicle, install the remaining 2
mounting bolts attaching the ICU to the mounting
bracket (Fig. 16). Tighten all 3 mounting bolts to a
torque of 11 N´m (97 in. lbs.).
(3) Install the dash seal and three mounting
screws (Fig. 15).
(4) If equipped, install the silencer on top of the
dash seal (Fig. 15).
(5) Connect the steering shaft coupling and install
the pinch bolt (Fig. 15). Tighten the pinch bolt to 28
N´m (250 in. lbs.).
(6) Remove the steering wheel holder.
CAUTION: Because of the flexible section in the pri-
mary and secondary brake tubes, the brake tubes
must be held in proper orientation when tightened
and torqued. These tubes must not contact eachother or other vehicle components when installed.
Also, after the brake tubes are installed on the HCU,
ensure all spacer clips are reinstalled on the brake
tubes.
(7) Install the primary and secondary brake tubes
into their correct port locations on the HCU valve
block (Fig. 14). Tighten the tube nuts to a torque of
17 N´m (145 in. lbs.).
CAUTION: When installing the chassis brake tubes
on the HCU valve block, they must be located cor-
rectly in the valve block to ensure proper ABS oper-
ation.
NOTE: The chassis brake tube attachment locations
to the HCU, are marked on the bottom of the CAB.
(8) Install the (4) chassis brake tubes into their
correct port locations on the HCU valve block as
shown (Fig. 14). Tighten the tube nuts to a torque of
17 N´m (145 in. lbs.).
NOTE: Before installing the 24±way connector in
the CAB be sure the seal is properly installed in the
connector.
(9) Install the 24±way connector on the CAB by,
first, positioning the 24±way connector in the socket
of the CAB and carefully pushing it down as far as
possible. Once connector is fully seated by hand into
the CAB socket, push down on connector lock. This
will pull the connector into the socket of the CAB
and lock it in the installed position.
(10) Install any routing clips on the brake tubes.
(11) Remove the brake pedal holder.
(12) Install the speed control servo with its mount-
ing nuts.
(13) Connect the wiring harness to the speed con-
trol servo.
(14) Install the battery tray (Refer to 8 - ELEC-
TRICAL/BATTERY SYSTEM/TRAY - INSTALLA-
TION).
(15) Install the screw securing the coolant filler
neck to the battery tray.
(16) Reconnect the vacuum hose connector at the
tank built into the battery tray.
(17) Install the battery (Refer to 8 - ELECTRI-
CAL/BATTERY SYSTEM/BATTERY - INSTALLA-
TION).
(18) Install the battery shield.
(19) Remove the brake pedal holder.
(20) Connect negative cable back on negative post
of the battery.
(21) Bleed the Base and ABS brake hydraulic sys-
tems (Refer to 5 - BRAKES - STANDARD PROCE-
DURE).
Fig. 24 (TYPICAL) Remove/Install CAB
1 - CAB
2 - HCU VALVES
3 - HCU VALVE BLOCK
5 - 94 BRAKES - ABSRS
ICU (INTEGRATED CONTROL UNIT) (Continued)

(22) Road test vehicle to ensure proper operation
of the base and antilock brake systems.
INSTALLATION - RHD
(1) Install the ICU on the mounting bracket (Fig.
21). Install the 3 bolts (Fig. 21) attaching the ICU to
the mounting bracket. Tighten the 3 mounting bolts
to a torque of 11 N´m (97 in. lbs.).
CAUTION: The ICU mounting bracket to front sus-
pension cradle mounting bolts have a unique corro-
sion protection coating and a special aluminum
washer. For this reason, only the original, or origi-
nal equipment Mopar replacement bolts can be
used to mount the ICU bracket to the front suspen-
sion crossmember.
(2) Install the ICU and its mounting bracket as an
assembly on the front suspension crossmember.
Install the 3 bolts attaching the ICU bracket to the
crossmember (Fig. 20). Tighten the 3 mounting bolts
to a torque of 28 N´m (250 in. lbs.).
CAUTION: Because of the flexible section in the pri-
mary and secondary brake tubes, and the brake
tubes between the HCU and the proportioning
valve, the brake tubes must be held in proper ori-
entation when tightened and torqued. These tubes
must not contact each other or other vehicle com-
ponents when installed. Also, after the brake tubes
are installed on the HCU, ensure all spacer clips are
reinstalled on the brake tubes.
CAUTION: When installing the chassis brake tubes
on the HCU valve block, they must be located cor-
rectly in the valve block to ensure proper ABS oper-
ation. Refer to (Fig. 19) for the correct chassis
brake tube locations.
NOTE: The chassis brake tube attachment locations
to the HCU, are marked on the bottom of the ICU
mounting bracket.
(3) Install the 6 chassis brake tubes into their cor-
rect port locations on the HCU valve block as shown
in (Fig. 19). Tighten the tube nuts to a torque of 17
N´m (145 in. lbs.).
NOTE: Before installing the 24-way connector in the
CAB be sure the seal is properly installed in the
connector.(4) Install the 24-way connector (Fig. 17) on the
CAB using the following procedure. Position the
24-way connector in the socket of the CAB and care-
fully push it down as far as possible. When connector
is fully seated by hand into the CAB socket, push in
the connector lock (Fig. 18). This will pull the connec-
tor into the socket of the CAB and lock it in the
installed position.
NOTE: The CAB wiring harness must be clipped to
the ICU mounting bracket. This will ensure the wir-
ing harness is properly routed and does not contact
the brake tubes or the body of the vehicle.
(5) Clip the cab wiring harness (Fig. 17) to the
ICU mounting bracket.
(6) Install the routing clips (Fig. 25) on the brake
tubes.
(7) Lower the vehicle.
(8) Connect negative cable back on negative post of
the battery.
(9) Bleed the base and ABS hydraulic systems.
(Refer to 5 - BRAKES - STANDARD PROCEDURE)
(10) Road test vehicle to ensure proper operation
of the base and antilock brake systems.
Fig. 25 Brake Tube Routing Clips
1 - ROUTING CLIP
2 - HCU
3 - BRAKE TUBES
4 - ROUTING CLIP
RSBRAKES - ABS5-95
ICU (INTEGRATED CONTROL UNIT) (Continued)

BRAKES
TABLE OF CONTENTS
page page
BRAKES - BASE DESCRIPTION DESCRIPTION - BASE BRAKES ...........3
DESCRIPTION - BASE BRAKES (EXPORT) . . . 3
OPERATION - BASE BRAKES ..............3
WARNING .............................3
CAUTION ..............................4
DIAGNOSIS AND TESTING - BASE BRAKE SYSTEM .............................4
STANDARD PROCEDURE - BASE BRAKE BLEEDING ............................7
SPECIFICATIONS BRAKE FASTENER TORQUE .............8
SPECIAL TOOLS BASE BRAKE SYSTEM ..................9
BRAKE FLUID LEVEL SWITCH DESCRIPTION ..........................9
OPERATION ............................9
REMOVAL .............................10
INSTALLATION .........................10
ADJUSTABLE PEDALS SWITCH REMOVAL .............................10
INSTALLATION .........................10
HYDRAULIC/MECHANICAL DESCRIPTION DESCRIPTION - DISC BRAKES (FRONT) . . . 10
DESCRIPTION - DISC BRAKES (REAR) ....12
DESCRIPTION - DISC BRAKES (EXPORT) . . 12
DESCRIPTION - DRUM BRAKES (REAR) . . . 12
OPERATION OPERATION - DISC BRAKES (FRONT) .....12
OPERATION - DISC BRAKES (REAR) ......13
DIAGNOSIS AND TESTING - DRUM BRAKE AUTOMATIC ADJUSTER ................13
BRAKE LINES DESCRIPTION - BRAKE TUBES AND HOSES . 13
OPERATION - BRAKE TUBES AND HOSES . . . 13
INSPECTION - BRAKE TUBES AND HOSES . . . 13
BRAKE PADS/SHOES - FRONT REMOVAL REMOVAL - FRONT DISC BRAKE SHOES(CONTINENTAL TEVES BRAKES) .........14
REMOVAL - FRONT DISC BRAKE SHOES (TRW BRAKES) .......................14
CLEANING - DISC BRAKE SHOES ..........15
INSPECTION - DISC BRAKE SHOES ........15
INSTALLATION INSTALLATION - FRONT DISC BRAKESHOES (CONTINENTAL TEVES BRAKES) . . . 15 INSTALLATION - FRONT DISC BRAKE
SHOES (TRW BRAKES) ................16
BRAKE PADS/SHOES - REAR DISC REMOVAL - REAR DISC BRAKE SHOES .....16
CLEANING - DISC BRAKE SHOES ..........17
INSPECTION - DISC BRAKE SHOES ........17
INSTALLATION - REAR DISC BRAKE SHOES . . 18
BRAKE PADS/SHOES - REAR DRUM REMOVAL - REAR DRUM BRAKE SHOES ....18
INSPECTION - REAR DRUM BRAKE SHOE LINING ..............................21
INSTALLATION - REAR DRUM BRAKE SHOES . 21
ADJUSTMENTS ADJUSTMENT - REAR DRUM BRAKESHOES .............................22
DISC BRAKE CALIPER - FRONT REMOVAL REMOVAL - FRONT DISC BRAKE CALIPER(CONTINENTAL TEVES BRAKES) .........23
REMOVAL - FRONT DISC BRAKE CALIPER (TRW BRAKES) .......................23
DISASSEMBLY DISASSEMBLY - CALIPER GUIDE PINBUSHINGS (CONTINENTAL TEVES
BRAKES) ............................23
DISASSEMBLY - CALIPER PISTON AND SEAL ...............................23
CLEANING - CALIPER ...................24
INSPECTION - CALIPER ..................24
ASSEMBLY ASSEMBLY - CALIPER GUIDE PINBUSHINGS (CONTINENTAL TEVES
BRAKES) ............................24
ASSEMBLY - CALIPER PISTON AND SEAL . . 25
INSTALLATION INSTALLATION - FRONT DISC BRAKECALIPER (CONTINENTAL TEVES
BRAKES) ............................26
INSTALLATION - FRONT DISC BRAKE CALIPER (TRW BRAKES) ...............26
DISC BRAKE CALIPER - REAR REMOVAL - REAR DISC BRAKE CALIPER ....26
DISASSEMBLY - CALIPER PISTON AND SEAL . 27
CLEANING - CALIPER ...................28
INSPECTION - CALIPER ..................28
ASSEMBLY - CALIPER PISTON AND SEAL . . . 28
INSTALLATION - REAR DISC BRAKE CALIPER ............................29
RS BRAKES5s-1

DISC BRAKE CALIPER ADAPTERREMOVAL - FRONT DISC BRAKE CALIPERADAPTER ...........................30
INSTALLATION - FRONT DISC BRAKE CALIPER ADAPTER ....................30
DISC BRAKE CALIPER GUIDE PINS REMOVAL - DISC BRAKE CALIPER GUIDEPINS (TRW BRAKES) ..................30
INSTALLATION - DISC BRAKE CALIPER GUIDE PINS (TRW BRAKES) .............30
DRUM REMOVAL .............................31
INSTALLATION .........................31
FLUID DIAGNOSIS AND TESTING - BRAKE FLUIDCONTAMINATION .....................31
STANDARD PROCEDURE - BRAKE FLUID LEVEL CHECKING .....................31
SPECIFICATIONS BRAKE FLUID ........................32
JUNCTION BLOCK DESCRIPTION - NON-ABS JUNCTION BLOCK . 32
OPERATION - NON-ABS JUNCTION BLOCK . . 32
REMOVAL - NON-ABS JUNCTION BLOCK ....32
INSTALLATION - NON-ABS JUNCTION BLOCK . 32
MASTER CYLINDER DESCRIPTION DESCRIPTION ........................33
DESCRIPTION - RHD ..................34
OPERATION ...........................34
STANDARD PROCEDURE - MASTER CYLINDER BLEEDING ..................34
REMOVAL REMOVAL - LHD ......................35
REMOVAL - RHD ......................36
DISASSEMBLY - MASTER CYLINDER (FLUID RESERVOIR) .........................36
ASSEMBLY - MASTER CYLINDER (FLUID RESERVOIR) .........................37
INSTALLATION INSTALLATION - LHD ..................37
INSTALLATION - RHD ..................38
PEDALS - ADJUSTABLE REMOVAL .............................38
INSTALLATION .........................40
PEDAL TORQUE SHAFT - RHD REMOVAL .............................42
INSTALLATION .........................43
POWER BRAKE BOOSTER DESCRIPTION .........................43
OPERATION ...........................44
DIAGNOSIS AND TESTING - POWER BRAKE BOOSTER ...........................44
REMOVAL REMOVAL - LHD ......................45
REMOVAL - RHD ......................47 INSTALLATION
INSTALLATION - LHD ..................49
INSTALLATION - RHD ..................50
PROPORTIONING VALVE DESCRIPTION - PROPORTIONING VALVE(HEIGHT SENSING) ....................51
OPERATION - PROPORTIONING VALVE (HEIGHT SENSING) ....................51
DIAGNOSIS AND TESTING - PROPORTIONING VALVE (HEIGHT
SENSING) ...........................52
REMOVAL - PROPORTIONING VALVE (HEIGHT SENSING) ....................53
INSTALLATION - PROPORTIONING VALVE (HEIGHT SENSING) ....................53
ROTOR DIAGNOSIS AND TESTING - BRAKE ROTOR . . 54
STANDARD PROCEDURE - BRAKE ROTORMACHINING ..........................56
REMOVAL - FRONT BRAKE ROTOR ........57
INSTALLATION - FRONT BRAKE ROTOR .....57
SPECIFICATIONS BRAKE ROTOR .......................57
BRAKE ROTOR - EXPORT ..............58
SUPPORT PLATE - DRUM BRAKE REMOVAL .............................58
INSTALLATION .........................58
WHEEL CYLINDERS REMOVAL .............................59
INSPECTION ..........................59
INSTALLATION .........................60
PARKING BRAKE DESCRIPTION DESCRIPTION ........................60
DESCRIPTION - EXPORT ...............60
OPERATION ...........................60
STANDARD PROCEDURE STANDARD PROCEDURE - PARKINGBRAKE AUTOMATIC ADJUSTER TENSION
RELEASE ...........................61
STANDARD PROCEDURE - PARKING BRAKE AUTOMATIC ADJUSTER TENSION
RESET .............................61
CABLES - PARKING BRAKE REMOVAL REMOVAL - PARKING BRAKE CABLE(FRONT) ............................62
REMOVAL - PARKING BRAKE CABLE (INTERMEDIATE) ......................62
REMOVAL - PARKING BRAKE CABLE (RIGHT REAR) ........................63
REMOVAL - PARKING BRAKE CABLE (LEFT REAR )..............................64
INSTALLATION INSTALLATION - PARKING BRAKE CABLE(FRONT) ............................65
5s - 2 BRAKESRS

INSTALLATION - PARKING BRAKE CABLE(INTERMEDIATE) ......................66
INSTALLATION - PARKING BRAKE CABLE (RIGHT REAR) ........................66
INSTALLATION - PARKING BRAKE CABLE (LEFT REAR) .........................66
ADJUSTMENTS ADJUSTMENT - PARKING BRAKE CABLES . 66
CABLES - PARKING BRAKE (EXPORT) REMOVAL - FRONT CABLE ...............67
INSTALLATION - FRONT CABLE ............67
LEVER - PARKING BRAKE REMOVAL .............................67 INSTALLATION
.........................67
LEVER - PARKING BRAKE (EXPORT) REMOVAL - PARKING BRAKE LEVER ANDFRONT CABLE .......................68
INSTALLATION - PARKING BRAKE LEVER AND FRONT CABLE ...................69
SHOES - PARKING BRAKE REMOVAL .............................69
INSTALLATION .........................75
ADJUSTMENTS ADJUSTMENT - PARKING BRAKE SHOES . . 76
BRAKES - BASE
DESCRIPTION
DESCRIPTION - BASE BRAKES
The base brake system consists of the following
components: ² Brake pedal
² Power brake booster
² Master cylinder
² Brake tubes and hoses
² Proportioning valve (non-ABS vehicles only)
² Disc brakes
² Drum brakes
² Brake lamp switch
² Brake fluid level switch
² Parking brakes
Front disc brakes control the braking of the front
wheels; rear braking is controlled by rear drum
brakes or rear disc brakes depending on options. The hydraulic brake system is diagonally split on
both the non-antilock braking systems and antilock
braking systems. That means the left front and right
rear brakes are on one hydraulic circuit and the right
front and left rear are on the other. For information on the brake lamp switch, (Refer
to 8 - ELECTRICAL/LAMPS/LIGHTING - EXTERI-
OR/BRAKE LAMP SWITCH - DESCRIPTION) Vehicles equipped with the optional antilock brake
system (ABS) use a system designated Mark 20e. It
is available with or without traction control. This
system shares most base brake hardware used on
vehicles without ABS. ABS components are described
in detail in ANTILOCK BRAKE SYSTEM.
DESCRIPTION - BASE BRAKES (EXPORT)
Four-Wheel Disc Antilock Brakes are standard on
all models.
OPERATION - BASE BRAKES
When a vehicle needs to be stopped, the driver
applies the brake pedal. The brake pedal pushes the
input rod of the power brake booster into the booster.
The booster uses vacuum to ease pedal effort as force
is transferred through the booster to the master cyl-
inder. The booster's output rod pushes in the master
cylinder's primary and secondary pistons applying
hydraulic pressure through the chassis brake tubes
to the brakes at each tire and wheel assembly. The parking brakes are foot-operated. When
applied, the parking brake lever pulls on cables that
actuate brake shoes at each rear wheel. These shoes
come in contact with a hub mounted drum (drum for
disc/drum brakes or drum-in-hat for disc/disc brakes)
and hold it in place.
WARNING
WARNING: DUST AND DIRT ACCUMULATING ON
BRAKE PARTS DURING NORMAL USE MAY CON-
TAIN ASBESTOS FIBERS FROM PRODUCTION OR
AFTERMARKET BRAKE LININGS. BREATHING
EXCESSIVE CONCENTRATIONS OF ASBESTOS
FIBERS CAN CAUSE SERIOUS BODILY HARM.
EXERCISE CARE WHEN SERVICING BRAKE
PARTS. DO NOT SAND OR GRIND BRAKE LINING
UNLESS EQUIPMENT USED IS DESIGNED TO CON-
TAIN THE DUST RESIDUE. DO NOT CLEAN BRAKE
PARTS WITH COMPRESSED AIR OR BY DRY
BRUSHING. CLEANING SHOULD BE DONE BY
DAMPENING THE BRAKE COMPONENTS WITH A
FINE MIST OF WATER, THEN WIPING THE BRAKE
COMPONENTS CLEAN WITH A DAMPENED CLOTH.
DISPOSE OF CLOTH AND ALL RESIDUE CONTAIN-
ING ASBESTOS FIBERS IN AN IMPERMEABLE
CONTAINER WITH THE APPROPRIATE LABEL. FOL-
LOW PRACTICES PRESCRIBED BY THE OCCUPA-
TIONAL SAFETY AND HEALTH ADMINISTRATION
(OSHA) AND THE ENVIRONMENTAL PROTECTION
AGENCY (EPA) FOR THE HANDLING, PROCESSING,
AND DISPOSING OF DUST OR DEBRIS THAT MAY
CONTAIN ASBESTOS FIBERS.
RS BRAKES5s-3

CAUTION
CAUTION: During service procedures, grease or
any other foreign material must be kept off brake
shoes and braking surfaces of brake rotor or drum,
and external surfaces of hub and bearing assembly.
CAUTION: Brake rotor and caliper handling must be
done in such a way as to avoid damage to the rotor,
especially the machined surfaces, and scratching or
nicking of the brake linings.
CAUTION: Only the recommended jacking or hoist-
ing procedures for this vehicle are to be usedwhenever it is necessary to lift a vehicle. Failure to
raise a vehicle utilizing the recommended lift points
can result in damage to the vehicle. (Refer to
LUBRICATION & MAINTENANCE/HOISTING - STAN-
DARD PROCEDURE)
DIAGNOSIS AND TESTING - BASE BRAKE
SYSTEM
NOTE: There are three diagnosis charts following
that cover the RED BRAKE WARNING INDICATOR
LAMP, BRAKE NOISE and OTHER BRAKE CONDI-
TIONS.
RED BRAKE WARNING INDICATOR LAMP
CONDITION POSSIBLE CAUSES CORRECTION
RED BRAKE WARNING
LAMP ON 1. Parking brake lever not fully
released. 1. Release parking brake lever.
2. Parking brake warning lamp
switch on parking brake lever. 2. Inspect and replace switch as necessary.
3. Brake fluid level low in reservoir. 3. Fill reservoir. Check entire system for leaks. Repair or replace as required.
4. Brake fluid level switch. 4. Disconnect switch wiring connector. If lamp goes out, replace switch.
5. Mechanical instrument cluster
(MIC) problem. 5. Refer to appropriate Diagnostic
information.
6. Amber ABS Warning Indicator
Lamp also illuminated. 6. Refer to appropriate Diagnostic
information.
BRAKE NOISE
CONDITION POSSIBLE CAUSES CORRECTION
CLICK OR SQUAWK ON
PEDAL APPLICATION 1. Brake lamp switch. 1. Replace switch.
2. Brake Transmission Shift Interlock
Linkage. 2. Lubricate BTSI linkage.
3. Pedal pivot bushings 3. Lubricate pivot bushings. Replace if necessary.
DISC BRAKE CHIRP 1. Excessive brake rotor runout. 1. Follow brake rotor diagnosis and testing. Correct as necessary.
2. Lack of lubricant on brake caliper
slides. 2. Lubricate brake caliper slides.
3. Caliper/shoes not fully seated. 3. Reseat caliper/shoes.
DISC BRAKE RATTLE OR
CLUNK 1. Broken or missing anti-rattle
spring clips on shoes. 1. Replace brake shoes.
2. Caliper guide pins/bolts loose. 2. Tighten guide pins/bolts.
5s - 4 BRAKESRS
BRAKES - BASE (Continued)

CONDITION POSSIBLE CAUSES CORRECTION
DISC BRAKE SQUEAK AT
LOW SPEED (WHILE
APPLYING LIGHT BRAKE
PEDAL EFFORT) 1. Brake shoe linings. 1. Replace brake shoes.
DRUM BRAKE CHIRP 1. Lack of lubricant on brake shoe support plate where shoes ride. 1. Lubricate shoe contact areas on brake
shoe support plates.
DRUM BRAKE CLUNK 1. Drum(s) have threaded machined braking surface. 1. Replace brake drums as necessary.
DRUM BRAKE HOWL OR
MOAN 1. Lack of lubricant on brake shoe
support plate where shoes ride and
at the anchor. 1. Lubricate shoe contact areas on brake
shoe support plates and at the anchor.
2. Rear brake shoes. 2. Replace rear brake shoes.
DRUM BRAKE SCRAPING
OR WHIRRING 1. ABS wheel speed sensor or tone
wheel. 1. Inspect, correct or replace faulty
component(s).
SCRAPING (METAL-TO-
METAL). 1. Foreign object interference with
brakes. 1. Inspect brakes and remove foreign
object.
2. Brake shoes worn out. 2. Replace brake shoes. Inspect rotors and drums. Reface or replace as necessary.
OTHER BRAKE CONDITIONS
CONDITION POSSIBLE CAUSES CORRECTION
BRAKES CHATTER 1. Rear brake drum out of round or disc brake rotor has excessive
thickness variation. 1. Isolate condition as rear or front.
Reface or replace brake drums or
rotors as necessary.
BRAKES DRAG (FRONT
OR ALL) 1. Contaminated brake fluid. 1. Check for swollen seals. Replace all
system components containing rubber.
2. Binding caliper pins or bushings. 2. Replace pins and bushings.
3. Binding master cylinder. 3. Replace master cylinder.
4. Binding brake pedal. 4. Replace brake pedal.
5. Brake lamp switch not adjusted
properly and mounting bracket is
bent. 5. Straighten mounting bracket and
replace brake lamp switch.
BRAKES DRAG (REAR
ONLY) 1. Parking brake cables binding or
froze up. 1. Check cable routing. Replace cables
as necessary.
2. Parking brake cable return spring
not returning shoes. 2. Replace cables as necessary.
3. Service brakes not adjusted
properly (rear drum brakes only). 3. Follow the procedure listed in the
adjustment section.
4. Rear disc brake parking brake not
properly adjusted. Adjust parking brake shoes.
BRAKES GRAB 1. Contaminated brake shoe linings. 1. Inspect and clean, or replace shoes. Repair source of contamination.
2. Improper power brake booster
assist. 2. Refer to power brake booster
diagnosis and testing.
RS
BRAKES5s-5
BRAKES - BASE (Continued)

CONDITION POSSIBLE CAUSES CORRECTION
EXCESSIVE PEDAL
EFFORT 1. Obstruction of brake pedal. 1. Inspect, remove or move obstruction.
2. Low power brake booster assist
(vacuum leak). 2. Refer to power brake booster
diagnosis and testing.
3. Glazed brake linings. 3. Reface or replace brake rotors as necessary. Replace brake shoes.
4. Brake shoe lining transfer to brake
rotor. 4. Reface or replace brake rotors as
necessary. Replace brake shoes.
EXCESSIVE PEDAL
TRAVEL (VEHICLE STOPS
OK) 1. Air in brake lines. 1. Bleed brakes.
2. Rear drum brake auto-adjuster
malfunctioning.
2. Inspect and replace drum brake
components as necessary. Adjust rear
brakes.
EXCESSIVE PEDAL
TRAVEL (ONE FRONT
WHEEL LOCKS UP
DURING HARD BRAKING) 1. One of the two hydraulic circuits
to the front brakes is malfunctioning.
1. Inspect system for leaks. Check
master cylinder for internal malfunction.
PEDAL PULSATES/
SURGES DURING
BRAKING 1. Rear brake drum out of round or
disc brake rotor has excessive
thickness variation. 1. Isolate condition as rear or front.
Reface or replace brake drums or
rotors as necessary.
PEDAL IS SPONGY 1. Air in brake lines. 1. Bleed brakes. 2. Power brake booster runout
(vacuum assist). 2. Check booster vacuum hose and
engine tune for adequate vacuum
supply. Refer to power brake booster
diagnosis and testing.
PREMATURE REAR
WHEEL LOCKUP 1. Contaminated brake shoe linings. 1. Inspect and clean, or replace shoes.
Repair source of contamination.
2. Inoperative proportioning valve
(non-ABS vehicles). 2. Refer to proportioning valve
diagnosis and testing. Replace valve as
necessary.
3. Improper power brake booster
assist. 3. Refer to power brake booster in the
diagnosis and testing section.
STOP/BRAKE LAMPS
S TAY O N 1. Brake lamp switch out of
adjustment. 1. Replace brake lamp switch.
2. Brake pedal binding. 2. Inspect and replace as necessary.
3. Obstruction in pedal linkage. 3. Remove obstruction.
4. Power Brake Booster not allowing
pedal to return completely. 4. Replace power brake booster.
VEHICLE PULLS TO
RIGHT OR LEFT ON
BRAKING 1. Frozen brake caliper piston. 1. Replace frozen piston or caliper.
Bleed brakes.
2. Contaminated brake shoe lining. 2. Inspect and clean, or replace shoes. Repair source of contamination.
3. Pinched brake lines. 3. Replace pinched line.
5s - 6 BRAKESRS
BRAKES - BASE (Continued)

CONDITION POSSIBLE CAUSES CORRECTION4. Leaking piston seal. 4. Replace piston seal or brake caliper.
5. Suspension problem. 5. Refer to the Suspension group.
PARKING BRAKE -
EXCESSIVE HANDLE
TRAVEL 1. Rear drum brakes or rear disc
brake parking brake shoes out of
adjustment. 1. Adjust rear drum brake shoes, or
rear parking brake shoes on vehicles
with rear disc brakes.
STANDARD PROCEDURE - BASE BRAKE
BLEEDING
NOTE: This bleeding procedure is only for the vehi-
cle's base brakes hydraulic system. For bleeding
the antilock brakes hydraulic system, (Refer to 5 -
BRAKES - ABS - STANDARD PROCEDURE)
CAUTION: Before removing the master cylinder
cover, thoroughly clean the cover and master cylin-
der fluid reservoir to prevent dirt and other foreign
matter from dropping into the master cylinder fluid
reservoir.
NOTE: The following wheel sequence should be
used when bleeding the brake hydraulic system.
The use of this wheel sequence will ensure ade-
quate removal of all trapped air from the brake
hydraulic system.
² Left Rear Wheel
² Right Front Wheel
² Right Rear Wheel
² Left Front Wheel
NOTE: When bleeding the brake system, some air
may be trapped in the brake lines or valves far
upstream, as much as ten feet from the bleeder
screw (Fig. 1). Therefore, it is essential to have a
fast flow of a large volume of brake fluid when
bleeding the brakes to ensure all the air gets out. The brakes may be manually bled or pressure bled.
Refer to the appropriate following procedure.
MANUAL BLEEDING PROCEDURE
NOTE: Correct manual bleeding of the brakes
hydraulic system will require the aid of a helper.
NOTE: To adequately bleed the brakes using the
manual bleeding procedure the rear brakes must be
correctly adjusted. Prior to the manual bleeding of
the brake hydraulic system, correctly adjust the
rear brakes. (1) Pump the brake pedal three or four times and
hold it down before the bleeder screw is opened. (2) Push the brake pedal toward the floor and hold
it down. Then open the left rear bleeder screw at
least 1 full turn. When the bleeder screw opens the
brake pedal will drop all the way to the floor.
CAUTION: ªJust crackingº the bleeder screw often
restricts fluid flow, allowing only a slow, weak fluid
discharge of fluid. This practice will NOT get all the
air out. Make sure the bleeder is opened at least 1
full turn when bleeding.
(3) Release the brake pedal only afterthe bleeder
screw is closed. (4) Repeat steps 1 through 3, four or five times, at
each bleeder screw in the proper sequence. This
should pass a sufficient amount of fluid to expel all
the trapped air from the brake system. Be sure to
monitor the fluid level in the master cylinder, so it
stays at a proper level so air will not enter the brake
system through the master cylinder. (5) Check pedal travel. If pedal travel is excessive
or has not been improved, enough fluid has not
passed through the system to expel all the trapped
air. Continue to bleed system as necessary. (6) Perform a final adjustment of the rear brake
shoes (when applicable), then test drive vehicle to be
sure brakes are operating correctly and that pedal is
solid.
Fig. 1 Trapped Air In Brake Fluid Line
1 - TRAPPED AIR
RS BRAKES5s-7
BRAKES - BASE (Continued)